Method and device for monitoring inventory

ABSTRACT

A method and device for electronically controlling inventory utilizing multiple modularized integrated load cell weight indicating devices. An inventory monitoring system is provided having a central system controller and one or more modules. Each module includes a master integrated load cell weight indicating device having a microprocessor based controller, a communications controller, a A/D converter, and a weight indicating device. Connected to each master integrated load cell is one or more slave integrated load cell weight indicating devices not utilizing any separate communications controller or microprocessor-based controller. In practice, communications are implemented utilizing a data structure indicating a module address, a individual weight indicating device subaddress and a command and passed between the central system controller and the module. Both the integrated master and slave load cell include only a top platter and a load cell, with no base structure supporting the load cell. The present invention allows for multiple part inventory monitoring by reducing the costs of implementing and maintaining the monitoring system.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. provisionalapplication Ser. No. 60/173,853 filed Dec. 30, 1999.

TECHNICAL FIELD

[0002] In general, the present invention relates to inventory controlsystems, and in particular to a method and device for electronicallycontrolling inventory utilizing multiple modularized integrated loadcell weight indicating devices.

BACKGROUND OF THE INVENTION

[0003] Some conventional inventory monitoring systems utilize scales andbins to monitor the amount of inventory left within a customer site andto order appropriate replacements. Under such a system, a customer'ssite is installed with multiple scales, each scale having a bin locatedon top of the scale for receiving the inventory to be monitored.Inventory estimates are then calculated by determining a number of partsper weight ratio and multiplying it by the weight of the inventory inthe bin. For example, if the inventory in concern is a screw having aparts per number factor of 1 screw per 2 ounces, a weight reading by thescale of 100 ounces would indicate approximately 50 screws remained inthe bin. Accordingly, a supplier can monitor the weight of several binsand order replacements inventory as supply, and accordingly weight,decreases.

[0004] As applied to a larger customer, the conventional weightmonitoring system can require an investment, either by the customer orthe supplier, in a large number of scales to monitor a variety of parts.Because each individual part would likely have a different parts perweight ratio, a customer site having 300 different parts to be monitoredwould require an investment of 300 separate scales and bins to beconnected to the monitoring system.

[0005] Typically, the conventional scale for monitoring and reportingweight reading includes a multiple part platform assembly having aseparate top platter, constructed of metal or other suitable material, aload cell for detecting a weight, and a base for supporting the loadcell detecting the weight. Additionally, each scale typically has itsown microprocessor-based electronics to communicate weight data to themonitoring system. One such method of communicating electronics includeassigning an individual address to each scale/bin combination to beidentified by the monitoring system. As would be understood, a multiplepart assembly and individual electronics further burdens the systemsupplier (either the customer or inventory monitor) in a higher initialinvestment in scale equipment investments as well as increasedmaintenance costs. Thus, the number of scales required to monitorinventory coupled with the costs of the individual scale components andfeatures, creates a high cost for inventory monitoring.

[0006] Accordingly, there is a need for a more cost effective inventorymonitoring system which allows for individual monitoring of inventory,while reducing the implementation costs of the weight measuring andcommunication devices.

SUMMARY OF THE INVENTION

[0007] The present invention satisfies the above-described need byproviding a method and device for electronically controlling inventoryutilizing one or more weight indicating modules having multiple weightindicating devices connected to each module.

[0008] Generally described, the present invention provides an electronicweight indicating module. The module of the present invention includestwo or more weight indicating devices and a microprocessor. Themicroprocessor is in communication with the weight indicating devices,receives data indicative of a weight from the weight indicating devicesand communicates the data to an external source.

[0009] In another aspect of the present invention, an inventory controlsystem is provided. The inventory control system includes a centralsystem controller and a remote electronic weight indicating module. Theremote electronic weight indicating module has two or more weightindicating devices, and the central system receives data indicative ofweight from the weight indicating devices via the module.

[0010] In a further aspect of the present invention, a method ofcommunicating in an inventory control system is provided. The inventorycontrol system includes a central system controller and an electronicweight indicating module having two or more weight indicating devices isprovided. The method of communicating includes issuing data indicativeof a designation of a module, issuing data indicative of a designationof a weight indicating device within the module, and issuing dataindicative of a command associated with the weight indicating device.

[0011] In yet another aspect of the present invention, an integratedload cell weight indicating device is provided. The integrated load cellweight indicating device utilizes only a top platter, and an integratedload cell. The top platter is coupled to the load cell and the load cellincludes at least one leg for supporting the device without anadditional base structure.

[0012] Finally, in another aspect of the present invention an integratedload cell master weight indicating device is provided. The integratedload cell master weight indicating device utilizes only a top platter, aload cell, and a communications port. The top platter is coupled to theload cell, and the communications port is operatively connected to anoutput of the load cell. Additionally, the load cell includes at leastone leg for supporting the device without an additional base structure,and the communications port transmits data indicative of a weight to anexternal source.

[0013] The method and devices of the present invention allow multipleweight indicating devices to be coupled to one or more weight indicatingmodules without requiring each individual weight indicating device toutilize a separate communications controller or separate microprocessorbased logic control. Preferably implemented in a master/slaveconfiguration, the present invention reduces the cost of implementationand maintenance in inventory monitoring systems.

BRIEF DESCRIPTION OF THE DRAWING

[0014] The present invention is described in detail below with referenceto the attached figures, wherein:

[0015]FIG. 1 is a block diagram of an electronic inventory monitoringsystem utilizing weight indicating modules of the present invention;

[0016]FIG. 2 is a chart illustrating a preferred command structureutilized by the weight indicating devices of the present invention;

[0017]FIG. 3 illustrates a preferred command data structure forcommunicating between the central system controller and a weightindicating device of the present invention;

[0018]FIG. 4 is an elevational view of the master integrated load cellof the present invention;

[0019]FIG. 5 is a top plan of the master integrated load cell of thepresent invention with cutouts demonstrating the preferred construction;

[0020]FIG. 6 is a sectional view of the master integrated load cell ofthe present invention;

[0021]FIG. 7 is a sectional view of the master integrated load cell ofthe present invention;

[0022]FIG. 8 is an elevational view of the slave integrated load cell ofthe present invention;

[0023]FIG. 9 is a top plan view of the slave integrated load cell of thepresent invention with cutouts demonstrating the preferred construction;and

[0024]FIG. 10 is a sectional view of the slave integrated load cell ofthe present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0025] The present invention provides a method and device forelectronically monitoring inventory utilizing weight indicating modules.FIG. 1 is block illustrating an electronic monitoring system, describedgenerally by the reference numeral 10. Preferably, system 10 includes atleast one weight indicating module, referenced generally by the numeral12, in communication with a central system controller 14. To calculatethe number of parts in inventory, module 12 communicates a weight of aparticular number of parts to the system controller 14 which calculatesthe number of parts in the bin by multiplying the weight of the parts bya parts per weight ratio.

[0026] As illustrated in FIG. 1, the system 10 includes multiple modules12 in communication with one another via a communications bus line 18,and further in communications with the system controller 14. Preferably,the modules 12 are connected in a daisy chain configuration utilizing aRS485 communication interface. As would be readily understood by someoneskilled in the relevant art, different communication configurations orcommunication interfaces are within the scope of the present invention.Moreover, a separate communications computer 26 may be incorporated intothe system to provide some on-location monitoring or to be an interfacebetween the modules 12 and the system controller 14.

[0027] Preferably, the modules 12 include a master weight indicatingdevice 15 having a communications controller 20, a central controller22, an analog to digital (A/D) converter 24. The central controller 22includes microprocessor based electronics for receiving digital weightindication signals from the weight indicating devices and converting thesignals into recognizable weight values. Communication controller 20preferably provides a two-way communications link between the weightindicating devices and the central system controller 14. A/D converter24 preferably convert analysis signals from the weight indicatingdevices to digital signals for processing. Preferably, master weightindicating device 15 also includes a weight indicating device 25.

[0028] Connected to each master weight indicating device 15 are one ormore slave weight indicating devices 16 which do not utilize separatecentral controllers 22 or communications controllers 20. Accordingly,the module 12 includes multiple weight indicating devices withoutrequiring each weight indicating device to maintain individualcommunications and processing functions.

[0029]FIGS. 4, 5, 6, and 7 illustrate the preferred master integratedload cell 27 weight indicating device of the present invention. Masterintegrated load cell 27 includes a top platter 28, which is preferablyconstructed of a metal or other suitable material such as composites.Top platter 28 covers the top of the master integrated load cell (asshown in FIG. 5) and covers portions of the four side walls (as shown inFIGS. 4, 6, and 7). Master integrated load cell 27 also includes a loadcell 30 for detecting weight and is supported by four legs 32,preferably constructed of a plastic material. Thus, no additional basesupport is required for the load cell 30, as conventionally done.

[0030]FIG. 6 is sectional view of the master integrated load cell 27 ofthe present invention. As illustrated in FIG. 6, as a bin containing theparts to be weighed (or any other object to be weighed) is placed on thetop platter 28, the platter experiences a downward force. The downwardforce is then translated to multiple spacers 36, which are in contactwith the load cell 30. Load cell 30 receives the downward force, andaccordingly produces a corresponding voltage indicative of the downwardforce. The corresponding voltage is converted to a digital signal by theA/D converter and transferred to the central controller. The centralcontroller can then convert the digital signal into weight data for themonitoring system or alternatively transfer the digital signal to thecentral system controller via the communications controller.

[0031] In another aspect of the present invention, and with relation toFIGS. 2 and 7, master integrated load cell 27 relays data indicative ofa weight to the monitoring system. As illustrated in FIG. 7, ports 40facilitate a preferred daisy chain connection between modules and allowboth data and power to be transmitted within the system to theindividual modules. Additionally, master integrated slave 27 includesdata ports 34 for receiving and transmitting data to and from the slavemodules 16. Preferably, the master integrated load cell 27 includes fiveadditional ports 34 for connection to the slave terminals 16. Moreover,communications bus 36 facilitates the transfer of the data to thecentral controller 22 and to the communications controller 20. As wouldbe readily understood, different number of communications port with themaster integrated load cell is within the scope of the presentinvention. Accordingly, master load cell 27 serves as a master weightindicating device 15 for the present invention.

[0032]FIGS. 8, 9 and 10 are illustrative of a preferred slave integratedload cell 42 of the present invention. Similar to the master integratedload cell, the slave integrated load cell 42 includes a top platter 28,preferably constructed of metal and overlapping the walls of the slaveintegrated load cell 42. Slave 42 also includes a load cell 30 and fourlegs 32 for supporting the slave 42. Additionally, slave 42 includes acommunication line 44 for coupling to the master weight indicatingdevice.

[0033] With reference to FIGS. 9 and 10, as a bin (or other object) isplaced on the top platter 28, the platter experiences a downward force.The downward force is then translated to multiple spacers 36, which arein contact with the load cell 30. Load cell 30 receives the downwardforce, and accordingly produces a corresponding voltage indicative ofthe force. No additional base support is required for the load cell 30,as conventionally done. The voltage produced by the load cell 30 is thentransferred externally, via communications link 46, to the external line44 to interface with a master weight indicating device. Similar to themaster integrated load cell, the corresponding voltage is converted to adigital signal by the master integrated load cell A/D converter andtransferred to the central controller. The central controller can thenconvert the digital signal into weight data for the monitoring system oralternatively transfer the digital signal to the central systemcontroller via the communications controller.

[0034] The present invention is described in association with a masterweight indicating device receiving data from additional slave indicatingdevices. As would be readily understood, the present invention couldalso be implemented with a separate module including the communicationcontroller and a module controller, but not having the additional weightindicating components. Accordingly, in this alternative, any number ofweight indicating devices, such as the slave weight indicating devices,would be coupled with the module.

[0035] Additionally, either of the weight indicating devices of thepresent could also include a display or other visual and/or audioindicator for alerting the customer site that one or more of the weightindicating devices may be inoperable or malfunctioning. Preferably, theindicating device is light emitting diode (LED) which would indicate anerror to be reported. One example of a possible configuration of the LEDindicator includes a green LED to indicate proper function and a red LEDto indicate an error. Another configuration involves a blinking LED toindicate an error, with the LED either lit continuously or unlit duringproper function. Yet another possible configuration of the LED indicatorwould include a lit LED (of any color) to indicate an error and an unlitLED to indicate proper function. As would be readily understood,additional indicators, including, but not limited to, horns, sirens, orother visual indicators, are within the scope of the present invention.

[0036] The present invention also provides a preferred communicationsprotocol for establishing two-way communications between the individualweight indicating devices and the monitoring system. Preferably, eachmodule within the system is referenced by an address indicative of themodule. Additionally, each weight indicating device is referenced by asubaddress indicative of the individual weight indicating device withinthe particular module. The subaddress allows the central systemcontroller 14 to communicate with a specific weight indicating device 16and for the central system controller 14 to identify which particularweight indicating device 16 is responding when receiving communications.Thus, the central system controller can use the communication protocolof the present invention to broadcast a message intended for only asingle weight indicating device over the communications line, and haveonly the appropriate weight indicating receive the communication.

[0037]FIG. 2 is a table illustrating a preferred calculate weightcommand issued to a module having 6 weight indicating devices. The tableincludes a heading 50 indicating an address for the particular module,in this example “27”. The table also includes a first column 52indicating a device subaddress, 0-5, and a second column 54 indicatingthe resulting command. With reference to FIG. 3, for illustrativepurpose, a preferred command data structure 56 would include a two digitplace 58 for indicating the address of module, a second two digit place60 for indicating a subaddress of the weight indicating device, and athird two digit place 62 for indicating the command relating to thecommunication.

[0038] With reference again to FIG. 2, if the command for telling theweight indicating device to transfer a weight reading is the numeral“05”, then the corresponding command to tell the third weight indicatingdevice to transfer the weight would be “27205” as illustrated at 64. Aswould be readily understood, modified or different data structures foridentifying the module or weight indicating device is within the scopeof the present invention.

[0039] Generally, and referring back to FIG. 1, central systemcontroller 14 sends commands to the modules 12 and receives data fromthe modules and/or the separate weight indicating devices 16.Preferably, the central system controller is further connected to anenterprise controller 66 for controlling various functions associatedwith the central system controller of the system 10. The enterprisecontroller 66 preferably controls an inventory system 68, an ordergenerating system 70, a customer order approval system 72, a billingsystem 74 and a reporting system 76. Each of these systems performdedicated tasks associated with monitoring inventory levels.Additionally, power controller 78 is in communications with the modules12 to provide power to the system. As would be readily understood,central system controller 14 may be a single or multiple systems.Additionally, power may be provided locally to each module 12.

[0040] It will be understood that certain features and subcombinationsare of utility and may be employed without reference to other featuresand subcombinations. This is contemplated by and is within the scope ofthe claims.

[0041] Since many possible embodiments may be made of the inventionwithout departing from the scope thereof, it is to be understood thatall matter herein set forth or shown in the accompanying drawings is tobe interpreted as illustrative, and not in a limiting sense.

We claim:
 1. An electronic weight indicating module, the modulecomprising: two or more weight indicating devices; and a microprocessor,the microprocessor in communication with the weight indicating devices;wherein the microprocessor receives data indicative of a weight from theweight indicating devices and communicates the data to an externalsource.
 2. The electronic weight indicating module as recited in claim 1, wherein the independent weight indicating devices are at least oneintegrated load cell.
 3. The electronic weight indicating module asrecited in claim 1 further comprising an analog to digital (A/D)converter, wherein the A/D converter is in communication with the two ormore weight indicating devices and processes communication signals fromweight indicating devices to be sent to the microprocessor.
 4. Theelectronic weight indicating module as recited in claim 3 , wherein theweight indicating devices provide an analog voltage signal correspondingto a weight, and wherein the A/D converter receives the voltage andconverts the analog signal to a digital weight signal.
 5. The electronicweight indicating module as recited in claim 4 , wherein themicroprocessor receives the digital weight signal and converts thedigital signal into data indicative of a weight.
 6. The electronicweight indicating module as recited in claim 4 , wherein a first of theweight indicating devices is a master weight indicating device, themaster weight indicating device housing the microprocessor.
 7. Theelectronic weight indicating module as recited in claim 6 , wherein themaster weight indicating device further includes a communicationscontroller, the communications controller operable to relay weightindicating data to the external source.
 8. The electronic weightindicating module as recited in claim 7 , wherein a second of the weightindicating devices is a slave weight indicating device, the slave weightindicating device in communication with and operably coupled to themaster weight indicating device.
 9. The electronic weight indicatingmodule as recited in claim 1 , wherein the weight indicating devices areindependent of each other.
 10. An inventory control system, the systemcomprising: a central system controller; and an electronic weightindicating module, the module comprising two or more weight indicatingdevices; wherein the central system receives data indicative of weightfrom the weight indicating devices via the module.
 11. The inventorycontrol system as recited in claim 10 , wherein the central systemcontroller communicates with the weight indicating devices via a datastructure containing a first weight indicating module identifying field,and a second weight indicating device identifying field.
 12. Theinventory control system as recited in claim 10 , wherein the moduleincludes a communication controller, and wherein the communicationcontroller receives data indicative of a weight from weight indicatingmodule to be passed to the central system controller.
 13. The inventorycontrol system as recited in claim 10 further comprising a remotecommunications terminal, the communications terminal receiving dataindicative of a weight from the module and transferring the data to thecentral system controller.
 14. The inventory control system as recitedin claim 10 further comprising a plurality of modules, each module incommunication with the central system controller.
 15. The inventorycontrol system as recited in claim 14 , wherein the modules communicatewith the central system controller via a communications bus.
 16. Theinventory control system as recited in claim 15 , wherein the modulesare coupled to the communications bus via a daisy chain connection. 17.The inventory control system as recited in claim 14 , wherein a first ofthe weight indicating devices is a master weight indicating device. 18.The inventory control system as recited in claim 17 , wherein a secondof the weight indicating devices is a slave weight indicating device,the slave weight indicating device in communication with and operablycoupled to the master weight indicating device.
 19. A method ofcommunicating in an inventory control system, the inventory controlsystem comprising a central system controller and an electronic weightindicating module having two or more weight indicating devices, themethod comprising: issuing data indicative of a designation of a module;issuing data indicative of a designation of a weight indicating devicewithin the first module; and issuing data indicative of a commandassociated with the weight indicating device.
 20. The method ofcommunicating as recited in claim 19 , wherein the data issuing stepsare executed by issuing a single data structure containing the dataindicative of the module, the weight indicating device, and the command.21. An integrated load cell weight indicating device, the deviceconsisting only of: a top platter; and a load cell, wherein the topplatter is coupled to the load cell; wherein the load cell includes atleast one leg for supporting the device without an additional basestructure.
 22. The integrated load cell weight indicating device asrecited in claim 21 , wherein the top platter and the integrated loadcell are coupled via a plurality of spacers, and wherein the spacerstransfer a downward force from the top platter to the integrated loadcell.
 23. An integrated load cell master weight indicating device, thedevice consisting only of: a top platter; a load cell, wherein the topplatter is coupled to the load cell; and a communications port, thecommunications port operatively connected to an output of the integratedload cell; wherein the load cell includes at least one leg forsupporting the device without an additional base structure; and whereinthe communications port transmits data indicative of a weight to anexternal source.
 24. The integrated load cell master weight indicatingdevice as recited in claim 23 , wherein the communications port receivesdata indicative of a weight from one or more slave weight indicatingdevices, and transmits the data to the external source.
 25. Theintegrated load cell master weight indicating device as recited in claim24 , wherein the slave weight indicating devices are integrated loadcells not utilizing a communications port.